As part of a research project to verify the transformative possibilities of 3D printing for concrete applications, Gate Precast used 3D printed forms in the production of interconnecting towers of One South First in Brooklyn, NY, clad exclusively with polished and acid-etched architectural precast concrete.
Through a design-assist relationship, Gate Precast, Two Trees and world-renowned architects COOKFOX refined some of the window profiles on the tower to make it cost effective and practical to use 3D printed forms. The multi-faceted window panels include aluminum framing and glass pre-assembled and caulked at Gate’s fabrication facilities prior to shipping to the jobsite, streamlining the installation of the façade.
Pre-installed windows conservatively saved eight months on the schedule of the Residential Tower (42 stories) and the Ten Grand Street Office Tower (22 stories) and allowed the interiors program to start earlier than the traditional delivery methods of windows.
The façade design is inspired by sugar’s crystalline structure, which connects the building with the industrial history of the Domino Sugar site. GATE utilized a super white, sand-rich mix to mimic the size, shape and color of sugar crystals. Casting on the 3D printed forms provided the added benefit of incredibly sharp details and improved finishes.